Cosmetic material sheet and method for manufacture of the sheet and apparatus for use in the manufacture

ABSTRACT

A cosmetic material sheet which comprises a sheet substrate  1  having, on an upper surface thereof, a large number of concave portions  5  arranged in a checkered pattern, a foundation layer  6  provided at a given position on the upper surface of the sheet substrate  1  in a state of covering arbitrary concave portions  5  out of a large number of concave portions  5,  and a protective cover  3  attached releaseably on the upper surface of the sheet substrate  1  in a state of covering the foundation layer  6,  wherein each concave portion  5  has an oblong shape in a plan view and has a bottom part thereof formed into a curved plane of a dish shape.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a cosmetic material sheet which enablesa trial use of a powdery cosmetic such as a foundation, an eye shadow, acheek color or the like hygienically as a sample, enables a sale thereofas a product and particularly enables a use thereof as a disposableproduct. The present invention also relates to a method formanufacturing of the same and an apparatus for use in the manufacture.

2. Related Art

Conventionally, in order to contain a sample of powdery cosmetics suchas a foundation, an eye shadow, a cheek color or the like, various kindsof sample cases have been marketed. However, all of them have astereoscopic or three-dimensional shape so that there has been a problemthat they are bulky and hence, it is difficult to handle them intransportation or the like.

There exists a conventional thin cosmetic sampler. As shown in FIG. 25,this cosmetic sample includes a cosmetic sample layer 62 having adesired pattern printed on an upper surface of a mount 61 by a screenprinting and a transparent protective cover 64 adhered to the uppersurface of the mount 61 by way of an adhesive agent layer 63 coated onan outer peripheral portion of the upper surface such that theprotective cover 64 can be peeled off. Then, in forming the cosmeticsample layer 62, as cosmetic material which includes the cosmetic samplelayer 62, material which dissolves powder which eventually becomes acosmetic sample in a solvent is used. Then, by printing such aslurry-like cosmetic material on the upper surface of the mount 61 by ascreen printing, the solvent in the cosmetic material is evaporated andthe cosmetic sample layer 62 remains.

However, the above-mentioned cosmetic sampler uses, as the cosmeticmaterial which constitutes the cosmetic sample layer 62, material whichdissolves powder which becomes the cosmetic sample in the solvent andhence, the cosmetic sampler can be used only as a color sample. Further,the color of the cosmetic sample layer 62 does not agree with the colorof the cosmetic actually used.

SUMMARY OF THE INVENTION

The present invention has been made in view of the above-mentionedcircumstance and it is an object of the present invention to provide acosmetic material sheet which can offer powdery cosmetic materialtotally having the same color, gloss and touch as those of powderymaterial actually used as a sample or the like and can firmly adhere thepowdery cosmetic material to a sheet substrate, a method formanufacturing such a cosmetic material sheet and a device used for sucha method.

According to one embodiment, a cosmetic material sheet of the presentinvention includes a sheet substrate having a large number of concaveportions formed on an upper surface thereof, a powdery cosmetic materialadhering layer formed on the upper surface of the sheet substrate at agiven position in a state that the powder cosmetic material adheringlayer covers arbitrary concave portions out of a large number of concaveportions, and a protective cover which is releaseably adhered to theupper surface of the sheet substrate in a state that the protectivecover covers the powdery cosmetic material adhering layer, wherein eachconcave portion has an oblong shape in a plan view and has a bottomportion thereof formed into a curved plane of a dish shape.

That is, according to the cosmetic material sheet of the presentinvention, at a given position on the upper surface of the sheetsubstrate which has a large number of concave portions on the uppersurface thereof, the powdery cosmetic material adhering layer is formedin a state that the powdery cosmetic material adhering layer coversarbitrary concave portions out of a large number of concave portions.Accordingly, by using a powdery cosmetic material that is actuallymanufactured for sale instead of a sample cosmetic material as thepowdery cosmetic material which constitutes the above-mentioned powderycosmetic material adhesive layer, different from a conventional productwhich uses the sample cosmetic material which is obtained by dissolvingpowdery cosmetic material actually used in a solvent or the like, it ispossible to offer the powdery cosmetic material having the same color,gloss and touch as those of the powdery cosmetic material actually usedas a sample. Accordingly, by actually trying out the powdery cosmeticmaterial, a consumer can accurately judge whether the powdery cosmeticmaterial which the consumer is going to purchase has the quality and huethat the consumer desires so that the cosmetic material sheet is usefulin promoting the sale of the powdery cosmetic material.

Further, the cosmetic material sheet uses the powdery cosmetic materialused as the powdery cosmetic material of the above-mentioned powderycosmetic material adhering layer and hence, the cosmetic material sheetcan be used as a product. Further, the powdery cosmetic materialadhering layer is formed in a state that the powdery cosmetic materialadhering layer covers the arbitrary concave portions of the large numberof concave portions arranged on the upper surface of the sheet substrateand hence, the powdery cosmetic material which constitutes the powderycosmetic material adhering layer is filled in the above-mentionedarbitrary concave portions. The powdery cosmetic material which isfilled in the arbitrary concave portions performs an anchoring effect sothat the powdery cosmetic material adhering layer is firmly adhered tothe sheet substrate. Further, the above-mentioned concave portions havean oblong shape in a plan view and have bottom portions thereof formedinto a curved plane of a dish shape so that the powdery cosmeticmaterial which is filled in the above-mentioned arbitrary concaveportions can be easily taken out by adhering the powdery cosmeticmaterial to a powder puff or the like whereby a substantially totalamount of the powdery cosmetic material which constitutes the powderycosmetic material adhering layer can be used.

According to the present invention, when a plate-like frame which has aheight thereof higher than a height of the above-mentioned powderycosmetic material adhering layer is laminated on the upper surface ofthe above-mentioned sheet substrate and a protective cover isreleaseably adhered to an upper surface of the plate-like frame, thereis no possibility that an upper surface of the above-mentioned powderycosmetic material adhering layer comes into contact with a lower surfaceof the protective cover so that even when the protective cover is peeledoff in the trial use of the cosmetic material sheet, the powderycosmetic material is hardly adhered to the lower surface of theprotective cover.

Then, a method for manufacturing a cosmetic material sheet includes astep for supplying a mount which has a large number of concave portionsformed on an upper surface thereof wherein each concave portion has anoblong shape in a plan view and has a bottom portion thereof formed intoa curved plane of a dish shape, a step for filling powdery cosmeticmaterial at a given position on the upper surface of the mount suppliedin the above-mentioned manner in a state that the powdery cosmeticmaterial covers the arbitrary concave portions among a large number ofconcave portions, a step for pressing the filled powdery cosmeticmaterial, a step for adhering lamination material to the upper surfaceof the mount after the mount passes the pressing in a state that thelamination material covers the pressed powdery cosmetic material, and astep for cutting given portions of the mount after the mount passes theadhesion of the lamination material thus obtaining a cut piece as acosmetic material sheet.

Further, a device for manufacturing a cosmetic material sheet accordingto the present invention includes a supply device which supplies amountwhich has a large number of concave portions formed on an upper surfacethereof wherein each concave portion has an oblong shape in a plan viewand has a bottom portion thereof formed into a curved plane of a dishshape, a filling device which fills powdery cosmetic material at a givenposition on the upper surface of the mount supplied from the supplydevice in a state that the powdery cosmetic material covers thearbitrary concave portions among a large number of concave portions, apress device which presses the powdery cosmetic material filled by thefilling device, a laminating device which adheres lamination material tothe upper surface of the mount after the mount passes the press devicein a state that the lamination material covers the pressed powderycosmetic material, and a cutting device which cuts given portions of themount after the mount passes the laminating device thus obtaining a cutpiece as a cosmetic material sheet.

That is, the method and device for manufacturing a cosmetic materialsheet according to the present invention enable the uniform andefficient manufacturing of the cosmetic material sheet which has theabove-mentioned excellent effects.

Further, in the method for manufacturing a cosmetic material sheetaccording to the present invention, when the mount is formed of astrip-like mount and the method includes a step which winds or takes upthe-strip-like mount after cutting the cosmetic material sheets, thecosmetic material sheets can be continuously manufactured. Otherfeatures and advantages of the invention will be appeared from thefollowing detailed description taken in conjunction with theaccompanying drawings that illustrate, by way of example, variousfeatures of embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing one embodiment of a cosmeticmaterial sheet of the present invention.

FIG. 2 is an exploded perspective view of the cosmetic material sheet,

FIG. 3 is a cross-sectional view of an essential part of the cosmeticmaterial sheet.

FIG. 4 is an explanatory view of concave portions of the cosmeticmaterial sheet.

FIG. 5 is a transverse cross-sectional view of the concave portions, and

FIG. 6 is a longitudinal cross-sectional view of the concave portions.

FIG. 7 is an explanatory view showing one embodiment of a device formanufacturing a cosmetic material sheet according to the presentinvention.

FIG. 8 is an explanatory view of a filling device of the manufacturingdevice, and

FIG. 9 and FIG. 10 are explanatory views of a press device.

FIG. 11 and FIG. 12 are explanatory views of a method for manufacturinga cosmetic material sheet according to the present invention.

FIG. 13 is a perspective view showing another embodiment of the cosmeticmaterial sheet of the present invention.

FIG. 14 is an exploded perspective view of the cosmetic material sheet.

FIG. 15 is a perspective view showing still another embodiment of thecosmetic material sheet of the present invention.

FIG. 16 is a cross-sectional view of an essential part of the cosmeticmaterial sheet.

FIG. 17 is an explanatory view of a method for manufacturing thecosmetic material sheet shown in FIG. 15 and FIG. 16.

FIG. 18 is an explanatory view of a cutting device in the device formanufacturing a cosmetic material sheet of the present invention and

FIG. 19 is an explanatory view showing the manner of operation of thecutting device.

FIG. 20, FIG. 21, FIG. 22 and FIG. 23 are views showing modifications ofthe concave portions.

FIG. 24 is a view showing a modification of the state of the arrangementof the concave portions.

FIG. 25 is a cross-sectional view of a conventional example.

PREFERRED EMBODIMENTS OF THE PRESENT INVENTION

Subsequently, the present invention is explained in detail.

According to one embodiment, a cosmetic material sheet of the presentinvention includes a sheet substrate on which a large number of concaveportions are formed, a powdery cosmetic material adhering layer and aprotective cover.

Various kinds of resin sheets including PP (polypropylene) resin sheetsor the like and various paper sheets including woodfree paper or thelike can be used as the sheet substrate. The thickness of the PP resinsheet is set to 6 to 400 μm, and more particularly, to 100 to 200 μm.

On the other hand, woodfree paper or paperboard is set to 80 to 500g/m², and more particularly to 180 to 310 g/m².

To take out a substantially amount of powdery cosmetic material adheredto the inside of the concave portions, each concave portion is requiredto have an oblong shape in a plan view and to have a bottom portionthereof formed into a curved plane of a dish shape. In the presentinvention, “oblong” means not only “elliptical” but also an “elongatedshape” as shown in FIG. 20. Further, “curved plane of a dish shape”means not only a shape of an earthen mortar or the like but also acurved shape having an acute angle as shown in FIG. 21 and a shapehaving a flat bottom surface as shown in FIG. 22 and FIG. 23 (a flatsurface being indicated by A in FIG. 22 as well as in FIG. 23). As amethod for forming such concave portions, a method which adoptsembossing (flat-pressure press forming or circular-pressure pressforming) or a method which adopts screen printing, photogravure printingor offset printing or the like can be used. Further, as a pattern forarranging a large number of such concave portions on the upper surfaceof the sheet substrate, various patterns including a checkered pattern,a staggered pattern, a radial pattern, a vortex pattern or the like or acombination of these patterns can be considered.

Further, the depth of the concave portions is set within a range of 1 to500 μm, and more particularly within a range of 1 to 300 μm. Further,the lateral width of the concave portions is set within a range of 50 to2000 μm, and more particularly within a range of 50 to 1000 μm.

Further, a longitudinal width of the concave portions is set within arange of 50 to 2000 μm, and more particularly within a range of 50 to1000 μm. Then, when the depth of the concave portions is set to 1 to 500μm, the lateral width is set to 50 to 2000 μm and the longitudinal widthis set to 50 to 2000 μm with respect to the concave portions, asubstantially total amount of powdery cosmetic material can be taken outwithout leaving the powdery cosmetic material in the inside of theconcave portions. Particularly, when the depth of the concave portionsis set to 1 to 300 μm, the lateral width is set to 50 to 1000 μm and thelongitudinal width is set to 50 to 1000 μm with respect to the concaveportions, a total amount of powdery cosmetic material can be removedeasily. Further, since the shape of the concave portions can be madesmall, the number of concave portions which can be formed on the uppersurface of the sheet substrate can be increased so that the removalpreventive property derived from the anchoring effect can be increased.Further, when the shape of the above-mentioned concave portions isformed in an elliptical shape, the lateral width indicates a length of along axis and the longitudinal width indicates a length of a short axis.

As a method which forms the powdery cosmetic material adhering layer onthe sheet substrate, it is preferable to use a method in which thepowdery cosmetic material mounted on a mesh of a printing plate isscrubbed down through the mesh and is applied to a desired position onthe sheet substrate using a brush and thereafter the powdery cosmeticmaterial is pressed Since the method uses the brush, bristles do notcollapse the powdery cosmetic material and hence, the quality of thepowdery cosmetic material is not deteriorated.

As the protective cover, lamination material or the like which is cut ina given shape by a cutting device of a manufacturing device which willbe explained later can be used. A transparent or a semi-transparentprotective cover such as a PET film or the like can be used. Thethickness of the PET film is set to 6 to 180 μm, and more particularlyto 25 to 75 μm.

It may be desirable to insert a plate-like frame between the sheetsubstrate and the protective cover. As the plate-like frame, a PET film,a woodfree paper or the like can be used. A thickness of the PET film isset to 6 to 300 μm, and more particularly to 50 to 150 μm. On the otherhand, the woodfree paper or the paperboard is set to 80 to 450 g/m², andmore particularly to 180 to 260 g/m².

As an adhesive agent which is used for laminating the sheet substrate,the plate-like frame and the protective cover, a room-temperaturecuring-type adhesive agent, a thermosetting-type adhesive agent, ahot-melt-type adhesive agent, a pressure-sensitive-type adhesive agentor the like can be used.

Further, as an adhesive agent which is used for laminating theprotective cover to the sheet substrate, a re-peeling type adhesiveagent (an adhesive agent of a type which performs an adhesion againafter peeling) or a weak-adhesion adhesive agent (an adhesive agentwhich makes the re-adhesion after peeling difficult).

FIG. 1 shows one embodiment of a cosmetic material sheet of the presentinvention. In this embodiment, the cosmetic material sheet includes asheet substrate 1, a plate-like frame 2 and a protective cover 3. Thesheet substrate 1 is formed of a milky-white PP resin sheet having athickness of 100 μm and a large number of concave portions 5 (see FIG.3) are formed on the entire surface of the upper surface in a checkeredpattern (see FIG. 4). In this embodiment, as shown in FIG. 4, theconcave portions 5 are arranged not only in the checkered pattern butalso in a state that a group consisting of five rows of the concaveportions 5 disposed close to each other are arranged in a staggeredpattern in two stages, that is, upper and lower stages, wherein thegroup consisting of five rows of the concave portions 5 in the upperstage enter the group consisting of five rows of the concave portions 5in the lower stage. These respective concave portions 5 (depth: 60 μm)are formed by embossing and have an elliptical shape (the length of thelong axis: 100 μm, the length of the short axis: 30 μm) in a plan viewas shown in FIG. 4 and have bottom surfaces thereof formed into a curvedplane of a mortar shape (or a dish shape) as shown in FIG. 5 and FIG. 6.

Numeral 6 indicates a foundation layer (powdery cosmetic materialadhering layer) which is formed on the upper surface of the sheetsubstrate 1 in a given shape (a quadrangular shape in this embodiment).A powdery foundation material 6 a, which is a cosmetic material actuallyproduced for sale is different from a sample cosmetic material.

The above-mentioned plate-like frame 2 is composed of a milky-white PETresin sheet (not shown in the drawing) having a thickness of 188 μm andan aluminum vapor-deposition layer having a thickness of 50 μm (notshown in the drawing) which is formed on the upper surface of the resinsheet. The plate-like frame 2 is laminated to the upper surface of theabove-mentioned sheet substrate 1 by way of a strong-adhesive agentlayer 7. In the plate-like frame 2, at a portion which corresponds tothe foundation layer 6, a window portion 2 a is formed such that theplate-like frame 2 surrounds the foundation layer 6. Further, a heightof the plate-like frame 2 is set higher than a height of the foundationlayer 6 such that a gap is formed between the foundation layer 6 and theprotective cover 3.

Further, the above-mentioned aluminum vapor-deposition layer is formedby vapor-depositing aluminum on an upper surface of the PET resin sheetin a usual manner. On the entire or a portion of the upper surface ofthe aluminum vapor-deposition layer, a product number, a color number orthe like is printed by silk printing or photogravure printing or thelike or a name of a cosmetic maker, a catch phrase, a trade mark, aproduct number, a retailer indication, a design, a ground pattern, otherinformation or the like is indicated.

The above-mentioned window portion 2 a is formed as an opening such thatthe window portion 2 a is approximately equal to or slightly smallerthan the foundation layer 6 in size. However, when the window portion 2a is formed such that it is slightly smaller than the foundation layer 6in size, even when the foundation layer 6 is formed such that it is madeslightly larger than a given size or is slightly displaced from an outerline, the window portion 2 a plays a role of a mask when the protectivecover 3 is laminated on the upper surface of the sheet substrate 1 sothat an advantageous effect that the foundation layer 6 appears to beformed at a given position through the window portion 2 a is obtained.

The shape of the window portion 2 a is configured in an arbitrary shapesuch as a rectangular shape, a circular shape, an elliptical shape, aheart shape, a lip shake, a lip stick shape or the like.

The protective cover 3 is formed of a transparent PET resin sheet havinga thickness of 75 μm. Due to a weak adhesive agent layer 8 which iscoated and formed on a portion of a lower surface of the protectivecover 3 which corresponds to the upper surface (that is, the entiresurface of the aluminum vapor-deposited layer) of the plate-like frame 2except for one corner portion (front left corner portion in the drawing)3 c, the protective cover 3 is releaseably adhered to the upper surfaceof the plate-like frame 2.

Then, since the height of the plate-like frame 2 is set higher than theheight of the foundation layer 6 in a state that protective cover 3 isadhered to the upper surface of the plate-like frame 2, the lowersurface of the protective cover 3 is not brought into contact with theupper surface of the foundation layer 6. Further, since the weakadhesive agent layer 8 is not coated or formed on one corner portion 3 cof the lower surface, the protective cover 3 can be easily peeled fromthe above-mentioned one corner portion 3 c.

The above-mentioned cosmetic material sheet can be manufactured by usinga manufacturing device shown in FIG. 7. In the drawing, numeral 11indicates a supply device which is arranged at one end portion (left endportion in the drawing) of the manufacturing device. A roller 12 aroundwhich a mount 10 is wound is rotatably supported on the supply device11. Further, a distal end of the mount 10 is pulled out toward the otherend side such that the distal end is wound around a roller 48 of thewinding device 19 which will be explained later and is arranged at theother end portion (a right end portion in the drawing) of themanufacturing device. The roller 12 of the supply device 11 and theroller 48 of the winding device 19 are designed to be controlled suchthat they are synchronously and intermittently driven. Further, a pairof front and rear rollers (not shown in the drawing) are arrangedbetween the supply device 11 and a base 13 which will be explained laterso as to make the mount 10 always droop between a pair of rollers. Dueto such a constitution, the mount 10 can have an excess in lengthbetween both rollers so that the mount 10 can be smoothly moved from oneend side to the other end side of the manufacturing device.

The mount 10 (made of the sheet substrate 1 in the embodiment shown inFIG. 1) is formed of a milky-white PP resin sheet having a thickness of100 μm and a large number of concave portions 5 (see FIG. 4 to FIG. 6)on the entire surface of the mount 10 in a checkered pattern. Further,on a rear surface of the mount 10, a printing such as the responsibilityindication or the like (not shown in the drawing) is performed at agiven interval in the longitudinal direction.

On an upper portion of the base 13, a filling device 15, a press device16, a lamination-device 17, a cutter device 18 and a winding device 19are mounted.

The filling device 15, as shown in FIG. 8, includes a printing plate 21,a brush 22, powdery cosmetic material supply means (not shown in thedrawing), printing plate moving means (not shown in the drawing) whichmoves the printing plate 21 in the upward and downward directions, andbrush moving means (not shown in the drawing).

The printing plate 21 includes a rectangular sheet body 21 a made ofpolypropylene (thickness: 0.5 mm) and a mesh 21 b made of silk GG16(thickness: 0.5 mm) formed at a given position of the rectangular sheetbody 21 a. The mesh 21 b is formed in a shape corresponding to the shapeof foundation layer 6 of the cosmetic material sheet.

The brush 22 is constituted of a large number of bristles 25 made ofnylon or polyethylene (diameter at proximal portions: 0.2 mm φ, totallength: 60 mm) having distal end thereof tapered, and a bristle holdingportion 26 which holds a large number of bristles 25 on a lower surfacethereof such that bristles 25 are extended downwardly. On an uppersurface of the bristle holding portion 26, a recessed portion 26 a whichaccommodates powdery foundation material 6 a is formed. The powderyfoundation material 6 a which is actually used as a product (cosmeticmaterial actually used) is supplied to and filled in the recessedportion 26 a from the powdery cosmetic supply means. Further, in abottom surface of the recessed portion 26 a, a plurality of throughholes 26 b (hole diameter: 3 mm φ) which are extended linearly to thelower surface of the bristle holding portion 26 (to be more specific,portions of the lower surface between respective bristles 25) are formedso that the powdery foundation material 6 a can be uniformly suppliedonto the mesh 21 b of the printing plate 21.

The brush moving means finely moves the brush 22 in the upward anddownward directions (vibrates the brush 22 with an amplitude of 1 mm)and performs one reciprocation (pitch: 1 second, 10 cm/stroke) in theleftward and rightward direction (that is, in the advancing direction ofthe mount 10).

The press device 16 includes, as shown in FIG. 9 and FIG. 10, a pressportion 27 of a pneumatic cylinder type (pressure: 0.3 kgf/cm², time:0.5 to 1.0 sec), a shock absorbing member 28 (made of an upper-sideshock absorbing urethane rubber layer 29 and a lower-side foamedurethane layer 30) which is mounted on a lower surface of the pressportion 27, a mesh 31 (material: silk) of XX7 which is disposed betweenthe shock absorbing member 28 and the mount 10, a shock absorbingurethane rubber plate 32 having a flat plate shape which is disposedbelow the mount 10, drive means (not shown in the drawings) which drivesthe press portion 27 in the upward and downward directions, a dustcollecting device 33 which sucks powdery material adhered to the mesh31, a dust collecting device 34 which sucks powdery material adhered tothe mount 10, and a pair of rollers 35 which are served for winding themesh 31 each time the pressing is performed. Both of these rollers 35are rotatable in a reverse manner. The mesh 31 is wound from one roller35 to the other roller 35 and when the mesh 31 is totally paid off fromone roller 35, these rollers are rotated in the reverse direction sothat mesh 31 is wound from the other roller 35 to one roller 35 so thatthey can be used semi-permanently.

Using these filling device 15 and press device 16, a given portion onthe upper surface of the mount 10 is coated with the powdery foundationmaterial 6 a in the following manner.

That is, first of all, upon completion of the preceding fillingoperation, the printing plate 21 is disposed at a position spaced apartfrom the mount 10. Subsequently, due to the intermittent driving of theroller 12 of the supply device 11 and the roller 48 of the windingdevice 19, a silk printing expected portion of the mount 10 is moved tothe lower side of the printing plate 21. Then, the printing plate 21 isdescended upon driving of the printing plate moving means so that themesh 21 b of the printing plate 21 is positioned above the silk printingexpected portion of the mount 10 with a given gap between them.Subsequently, the brush 22 is finely moved in the upward and downwarddirections upon driving of the brush moving means in one reciprocationin the leftward and rightward directions. Then, within onereciprocation, the powdery foundation material 6 a which is accommodatedin the recessed portion 26 a of the brush 22 is made to flow downthrough a large number of through holes 26 b and to fall on the mesh 21b. Subsequently, the powdery foundation material 6 a is pushed intoopenings of the mesh by the bristles 25 and is adhered to the uppersurface of the mount 10 (see FIG. 11). Here, since the brush 22 isfinely moved in the upward and downward directions, the mesh 21 b whichcomes into contact with the bristles 25 also finely moves and hence, thepowdery foundation material 6 a can easily fall from the apertures ofthe mesh 21 b so that the powdery foundation material 6 a is notcollapsed.

Then, in the press device 16, upon completion of the preceding pressingoperation, the press portion 27, the mesh 31 and the urethane rubberplate 32 are at positions spaced apart from the mount 10 (see FIG. 10).Subsequently, due to the above-mentioned intermittent movement, apressing expected portion (a portion where the powdery foundationmaterial 6 a is filled by the filling device 15) of the mount 10 is fedto the lower side of the pressing portion 27. Then, the pressing portion27 is descended upon actuation of the drive means so as to press theportion where the above-mentioned powdery foundation material 6 a isfilled. As a result, the foundation layer 6 (see FIG. 12) is formed onthe upper surface of the mount 10.

The lamination device 17 is a device provided for adhering laminationmaterial 37 to the upper surface of the mount 10. The above-mentionedlamination material 37 is includes a transparent PET resin sheet(eventually forming the protective cover 3 in the embodiment shown inFIG. 1) having a thickness of 75 μm, a weak adhesive agent layer whichis formed on a rear surface of the resin sheet, a frame (eventuallyforming the plate-like frame 2 in the embodiment shown in FIG. 1) whichis adhered to the weak adhesive agent layer and has a window portion 2 aformed therein at a portion corresponding to the foundation layer 6 onthe upper surface of the mount 10, and a strong adhesive agent layerformed on a rear surface of the frame. In FIG. 7, the resin sheet, theweak adhesive agent layer, the frame and the strong adhesive agent layerare not shown in the drawing.

The lamination device 17 includes, as shown in FIG. 7, a roller 40around which a lamination member 38 (member which is constituted byreleaseably adhering a peel-off member 39 which is formed by subjectingthe surface of the PET film to the mold release treatment using siliconeor the like on the strong adhesive agent layer formed on the rearsurface of the lamination material 37) is wound, a roller 41 which windsthe peel-off member 39 of the lamination member 38, and a roller 43which the lamination material 37 of the lamination member 38 passes. Thelamination member 38 which is wound around the roller 40 is pulled outtoward the other end side such that the distal end of the laminationmember 38 is wound around the roller 48 of the winding device 19. In themidst of the winding operation, after the lamination member 38 passesthe roller 42, the peel-off member 39, of the lamination member 38 iswound around the roller 41. On the other hand, in a state that thelamination material 37 of the lamination member 38 passes the roller 43,the lamination material 37 is adhered with pressure to the upper surfaceof the mount 10 on the outer peripheral surface of the roller 43. InFIG. 7, numeral 44 to 46 are provided for transporting the laminationmember 38.

The above-mentioned cutting device 18 cuts the mount 10 which has passedthe lamination device 17 so as to produce the cosmetic material sheetshown in FIG. 1. Further, with respect to the mount 10, the portionremaining after cutting the mount 10 with the cutting device 18 is woundaround the roller 48 of the winding device 19.

In this manner, in the above-mentioned embodiment, the cosmetic materialsheets can be manufactured continuously. Further, by using cosmeticmaterial actually used (cosmetic material having the same quality asthat of powdery cosmetics manufactured for sale) which is not a samplecosmetic material as the powdery foundation material 6 a, different froma conventional product which uses the sample cosmetic material which isobtained by dissolving cosmetic material actually used in a solvent orthe like, it becomes possible to offer the solid cosmetic materialhaving the same color, gloss and touch as those of the cosmetic materialactually used. Accordingly, by actually trying out the cosmetic materialmade of the solid cosmetic material, a consumer can accurately judgewhether the solid cosmetic material which the consumer is going topurchase has quality and hue that the consumer desires so that thecosmetic material sheet is greatly useful for promoting the sale of thesolid cosmetic material. Such a cosmetic material sheet may be usedeither a sample sheet or as a sheet for product.

Further, since there exists a gap between the upper surface of thefoundation layer 6 and the lower surface of the protective cover 3, whenthe protective cover 3 is peeled off, the powdery foundation material 6a of the foundation layer 6 is not adhered to the lower surface of theprotective cover 3. Further, it becomes possible to protect thefoundation layer 6 by shielding the foundation layer 6 from the outsideby the protective cover 3 and, at the same time, the appearance of thewhole cosmetic material sheet can be improved thus enhancing the valueof the cosmetic material sheet as a product. Still further, since thecosmetic material sheet is thin, it can be propagated in a state that itis filed in a filing portion of a weekly magazine, or in a state that itis used as an advertisement guide printed matter such as a direct mail,a post card, a letter, a catalogue, a pamphlet or in a form that it isattached to the advertisement guide printed matter.

FIG. 13 and FIG. 14 show the another embodiment of the cosmetic materialsheet according to the present invention.

In this embodiment, the plate-like frame 2 of the embodiment shown inFIG. 1 is not provided. Accordingly, in this embodiment, a protectivecover 3 is directly adhered to an upper surface of a sheet substrate 1by way of an adhesive agent layer 9. Further, the protective cover 3includes a quadrangular transparent window portion 3 a which is formedin the center of the protective cover 3 and a printing frame portion 3 bhaving a quadrangular frame shape which is formed around the transparentwindow portion 3 a. With respect to this printing frame portion 3 b, ona portion of a rear surface thereof except for one corner portion 3 c(front left corner portion in the drawing), the adhesive agent layer 9is formed and the protective cover 3 is releaseably adhered to the uppersurface of the sheet substrate 1 by way of this adhesive agent layer 9,Further, on a portion or on the entire surface of both surfaces of theprinting frame portion 3 b, a product number, a color number or the likeis printed by silk printing or photogravure printing or the like or aname of a cosmetic maker, a catch phrase, a trade mark, a productnumber, a retailer indication, a design, a ground pattern or otherinformation or the like is indicated. Other parts of this embodiment areidentical with those of the above-mentioned embodiment and hence,identical parts are indicated by the same numerals. This embodiment canalso achieve the same manner of operation and the same advantageouseffects as the above-mentioned embodiment. However, in this embodiment,since the cosmetic material sheet is not provided with the plate-likeframe 2, the upper surface of the foundation layer 6 and the lowersurface of the protective cover 3 are brought into contact with eachother.

Further, in this embodiment, at the time of manufacturing the cosmeticmaterial sheet, the lamination material 37 which is used in thelamination device 17 does not use the frame body. That is, thelamination material 37 includes a transparent PET resin sheet having athickness of 75 μm (eventually becoming the protective cover 3 in theembodiment shown in FIG. 13) and an adhesive agent layer (not shown inthe drawing) which is formed on a rear surface of the resin sheet at agiven position (portion corresponding to the printing frame portion 3 bof the protective cover 3 except for one corner portion 3 c).

FIG. 15 and FIG. 16 show still another embodiment of the cosmeticmaterial sheet according to the present invention. In this embodiment,three foundation layers 6 are formed on the upper surface of the sheetsubstrate 1 of the embodiment shown in FIG. 1 at an approximately equalinterval. Further, window portions 2 a are formed in the plate-likeframe 2 at portions thereof corresponding to the respective foundationlayers 6. Still further, two U-shaped incisions 51 which are extendedfrom the front end periphery of the protective cover 3 are formed in theprotective cover 3 at positions corresponding to the respective windowportions 2 a such that portions which are surrounded by the respectiveincisions 51 can be separated from the front end periphery of theprotective cover 3 by cutting. In FIG. 15, the strong adhesive agentlayer 7 and the weak adhesive agent layer 8 are not shown. Other partsof this embodiment are identical with those of the above-mentionedembodiments and hence, identical parts are indicated by the samenumerals. This embodiment can also achieve the same manner of operationand the same advantageous effects as the above-mentioned embodiments.

Such a cosmetic material sheet can be manufactured in the same manner asthe embodiment shown in FIG. 1. However, since three foundation layers 6are formed on the upper surface of the mount 10 (see FIG. 17) in thisembodiment, three sets of filling devices 15 shown in FIG. 7 and threesets of press devices 16 shown in FIG. 8 are provided. Here, when thepowdery foundation materials 6 a which are used in respective fillingdevices 15 are required to be different from each other in color, threecolors can be simultaneously formed.

Further, as shown in FIG. 18, the cutting device 18 includes a cutter 54which includes a full cutting tooth 52 (formed of a rectangular tooth)which cuts both of the mount 10 and the lamination material 37 and ahalf cut tooth 53 (formed of one long-side tooth and four short-sideteeth which are arranged in an equidistant manner within the fullcutting tooth 52) which cuts only the protective cover 3. The cuttingdevice 18 cuts the mount 10 which has passed the lamination device 17 asshown in FIG. 19. In FIG. 19, numeral 55 indicates cut lines (indicatedby chain lines) formed by the full cutting tooth 52 and numeral 56indicates half-cut lines (indicated by chain double-dashed lines) formedby the half-cut tooth 53. Respective cut pieces (not shown in thedrawing) which are cut in this manner are collected as the cosmeticmaterial sheets in a receiving base (not shown in the drawing). On theother hand, portions of the mount 10 remaining after the cuttingoperation are wound around the roller 48 of the winding device 19.

Although the cosmetic material sheets are manufactured continuously inthe above-mentioned respective embodiments, the cosmetic material sheetsmay be manufactured one by one. Further, in the above-mentionedrespective embodiments, a static eliminator may be provided to preventdust or the like from adhering to the lamination material 37 or thelike. Further, in the above-mentioned respective embodiments, as thesheet substrate 1, a sheet substrate which is formed by coating orlaminating a transparent PET resin film having a thickness of 12 μm ontoan upper surface of a woodfree paper (55 kg/m²) having a thickness of100 μm may be used. Still further, in the above-mentioned respectiveembodiments, the mesh 21 b of the printing plate 21 may be made ofnylon, PP resin, PE resin, Tetoron or stainless steel or the like.Further, by processing the mesh 31 of the press device 16, characterssuch as UV, patterns or the like may be indicated on the surface of thefoundation layer 6.

Further, as shown in FIG. 24, a large number of concave portions 5formed on the whole surface of the upper surface of the sheet substrate1 may be arranged obliquely such that groups which are respectively madeof five rows of neighboring concave portions in upper and lower stagesare arranged in a staggered pattern.

As has been described heretofore, according to the cosmetic materialsheet of the present invention, by using powdery cosmetic materialactually used (powdery cosmetic material having the same quality as thatof powdery cosmetic material manufactured for sale) which is not samplecosmetic material as the powdery cosmetic material which constitutes theabove-mentioned powdery cosmetic material adhesive layer, different froma conventional product which uses the sample cosmetic material which isobtained by dissolving powdery cosmetic material actually used in asolvent or the like, it becomes possible to offer the powdery cosmeticmaterial totally having the same color, gloss and touch as those of thepowdery cosmetic material actually used as a sample. Accordingly, byactually trying out the powdery cosmetic material, a consumer canaccurately judge whether the powdery cosmetic material which theconsumer is going to purchase has quality and hue which the consumerdesires so that the cosmetic material sheet is greatly useful forpromoting the sale of the powdery cosmetic material.

Further, the cosmetic material sheet according to the present inventionuses the powdery cosmetic material actually used as the powdery cosmeticmaterial of the above-mentioned powdery cosmetic material adhering layerand hence, the cosmetic material sheet can be used as a product.Further, powdery cosmetic material adhering layer is formed in a statethat the powdery cosmetic material adhering layer covers arbitraryconcave portions out of a large number of concave portions arranged onthe upper surface of the sheet substrate and hence, the powdery cosmeticmaterial which constitutes the powdery cosmetic material adhering layeris filled in the above-mentioned arbitrary concave portions. The powderycosmetic material which is filled in the arbitrary concave portionsperforms an anchoring effect so that the powdery cosmetic materialadhering layer is firmly adhered to the sheet substrate. Further, theabove-mentioned concave portions have an oblong shape in a plan view andhave bottom portions thereof formed into a curved plane of a dish shapeso that the powdery cosmetic material which is filled in theabove-mentioned arbitrary concave portions can be easily taken out byadhering the powdery cosmetic material to a powder puff or the likewhereby a substantially total amount of the powdery cosmetic materialwhich constitutes the powdery cosmetic material adhering layer can beused.

According to the present invention, when a plate-like frame which has aheight thereof higher than that of a height of the above-mentionedpowdery cosmetic material adhering layer is laminated on the uppersurface of the above-mentioned sheet substrate and a protective cover isreleaseably adhered to an upper surface of the plate-like frame, thereis no possibility that an upper surface of the above-mentioned powderycosmetic material adhering layer comes into contact with a lower surfaceof the protective cover so that even when the protective cover is peeledin the trial use of the cosmetic material sheet, the powdery cosmeticmaterial is hardly adhered to the lower surface of the protective cover.

Further, the method and device for manufacturing a cosmetic materialsheet according to the present invention enable the uniform andefficient manufacturing of the cosmetic material which has theabove-mentioned excellent effects.

1. A method for manufacturing a cosmetic material sheet comprising:supplying a mount which has a plurality of concave portions formed on anupper surface of the mount, wherein the depth of the concave portions iswithin a range of 1 to 500 μm, wherein the lateral width of the concaveportions is within a range of 50 to 2000 μm, wherein the longitudinalwidth of the concave portions is within a range of 50 to 2000 μm;filling powdery cosmetic material on the upper surface of the mountcovering the plurality of concave portions; pressing the filled powderycosmetic material; clearing the upper surface of the mount of powderycosmetic material; adhering lamination material to the upper surface ofthe mount, and the pressed powdery cosmetic material forming a powderycosmetic material adhering layer, wherein the lamination material isreleasably adherent, wherein the lamination material comprises a windowportion that is smaller than the powdery cosmetic material adheringlayer; and cutting the mount on a non-window portion of laminationmaterial to obtain a cut piece as a cosmetic material sheet.
 2. Themethod for manufacturing a cosmetic material sheet according to claim 1,wherein the mount is formed of a resin sheet or a woodfree paper.
 3. Themethod for manufacturing a cosmetic material sheet according to claim 2,wherein the resin sheet includes polypropylene.
 4. The method formanufacturing a cosmetic material sheet according to claim 3, whereinthe polypropylene resin sheet has a thickness of 6 to 400 μm.
 5. Themethod for manufacturing a cosmetic material sheet according to claim 3,wherein the polypropylene resin sheet has a thickness of 100 to 200 μm.6. A device for manufacturing a cosmetic material sheet comprising: asupply device which supplies a mount which has a plurality of concaveportions formed on an upper surface thereof, wherein the depth of theconcave portions is within a range of 1 to 500 μm, wherein the lateralwidth of the concave portions is within a range of 50 to 2000 μm,wherein the longitudinal width of the concave portions is within a rangeof 50 to 2000 μm; a filling device which fills powdery cosmetic materialon the upper surface of the mount wherein the powdery cosmetic materialcovers the concave portions to form a powdery cosmetic material adheringlayer; a pressing device which presses the powdery cosmetic material; ameans for clearing the upper surface of the mount of powdery cosmeticmaterial; a laminating device which adheres lamination material to theupper surface of the mount, wherein the lamination material isreleasably adherent, wherein the lamination material comprises a windowportion that is smaller than the powdery cosmetic material adheringlayer; and a cutting device which cuts the mount on a non-window portionof lamination material to obtain a cut piece as a cosmetic materialsheet.
 7. The device for manufacturing a cosmetic material sheetaccording to claim 6, wherein the mount is formed of a resin sheet or awoodfree paper.
 8. The device for manufacturing a cosmetic materialsheet according to claim 7, wherein the resin sheet includespolypropylene.
 9. The device for manufacturing a cosmetic material sheetaccording to claim 8, wherein the polypropylene resin sheet has athickness of 6 to 400 μm.
 10. The device for manufacturing a cosmeticmaterial sheet according to claim 8, wherein the polypropylene resinsheet has a thickness of 100 to 200 μm.
 11. The device for manufacturinga cosmetic material sheet according to claim 6, wherein the fillingdevice comprises a printing plate.
 12. The device for manufacturing acosmetic material sheet according to claim 6, wherein the filling devicecomprises a brush.
 13. The device for manufacturing a cosmetic materialsheet according to claim 6, wherein the filling device comprises apowdery cosmetic material supply means.
 14. The device for manufacturinga cosmetic material sheet according to claim 6, wherein the fillingdevice comprises a printing plate moving means.
 15. The device formanufacturing a cosmetic material sheet according to claim 14, whereinthe printing plate includes a mesh.
 16. The device for manufacturing acosmetic material sheet according to claim 6, wherein the filling devicecomprises a brush moving means.
 17. The device for manufacturing acosmetic material sheet according to claim 16, wherein the brush ismoved in the upward and downward directions, and is made to flow downthe powdery cosmetic material from the printing plate.